Method of applying padding to inner trim panels



March 12, 1940;

c. w. AVERY METHOD F APPLYING PADDING TO INNER TRIM PANELS Filed Nov. 1l, 1935 ATTORNEYS.

Patented Mar. 12, 1,940`

UNITED STATES" METHOD 0F APPLYING PADDING T0 INNER TRIM PANELS Clarence W. Avery, Detroit, Mich., assignor to The Murray Corporation of America, a corporation of Delaware Application November 11, 1935, Serial No. 49,140

3 Claims.

This invention relates to a novel metliod of preparing inner trim panels. More particularly, it relates to a processhaving to do with the application of padding material to backing sheets forming the basis of inner trim panels for use in automotive vehicles.

In the present day automobile body constructions, itas conventional to finish portions of the interior of automobile bodies with panel sections adapted to provide an attractive interior finish. 'Ifhese panels generally comprise a relatively stii cardboard backing sheet adapted to be secured directly to the frame work of the automobile body. The backing sheet is preferably covered with fibrous material or resilient padding of some sort and has a surface generally comprising fabric trim material sewed directly to the cardboard backing sheet. This unitary panel is then mounted in place interiorly of an automobile body and is generally retained in position by suitable battens, by garnish moldings, or other equivalent securing means.' l

It is a general object of the present invention to provide a rapid, continuous and satisfactory method of preparing backing sheets and particularly thel application of the padding material thereto.

The present invention contemplates the provision of a conveyor system in which a plurality of backing sheets may be rapidly serially prepared. Means are provided for rst covering the backing sheets with a substantially uniform layer of adhesive and automatic means are then pro- 'v vided for distributing a layer of non-woven fibrous material, such as comminuted jute bers, over the adhesive covered backing sheets. This fibrous material is thenfconsolidated and compacted in order that it will become strongly,A adhesively bonded to the backing sheets and the superuous fibrous material is then removed from the marginal edges of the backing sheet.

It is a further object of the present invention to provide a methodof preparing-panels of this general type in which the excess Vfibrous material 1 is removed from the marginal edges of the backing sheets in auniform and orderly manner amv in which successive backing sheets are give substantially identical treatment. Y It is particularly important in trim panels o padding, no unattractive irregularities be found at the marginal edges of the trim panel.

Many other and further objects and. advantages of the method herein disclosed will become apparent from the following specification when taken in connection with the accompanying drawing forminga part thereof.

In the drawing: l

Figure 1 is a perspective view of an inner trim panel of the type particularly adaptable for treatment by the method of the present invention;

Figure 2 is a sectional view taken on the line 2-2 of Figure 1, showing in detail the surface structure of the improved inner trim panel;

Figure 3 is a plan view of a machine particularly adaptable for practicing the method of the present invention;

Figure 4 is a side elevation of trated in Figure 3.

With more particular reference to the drawing, it will be seen that the method of the present invention is particularly adaptable for use in the preparation of inner trim panels, suchr as are shown in Figure 1. These panels comprise a section of backing material AI formed of cardboard or other suitable light, stiff sheet material which the machine illusthe panel is intended to cover. A mass of loose,

lnon-,woven brous material 2 is bonded to one surface of the panel by means of a layer of adhesivea3. The panel as a whole is then covered With a finish covering of fabric 4 which in its marginal edges may be adhesively secured to the back side of the backing sheet and may be stitched directly to the backing s heet along longitudinal linesof stitching 5.

AThe present invention is primarily. concerned with the application of the non-woven fibrous padding to the backing sheet in order to provide 'a padded surface ,thereon to which the fabric trim material may be applied in any conventional manner.

' While any suitable apparatus may be used for practicing the method taught herein, by way of illustration Figures 3 and .4 of the drawing more ,or less` diagrammaticallyillustrate one specific type of machinewhich has .beenfound particu- Ilarly satisfactory for' practicing the method of the present invention.

1 has an outer configuration cut in accordance with the particular section of the body interior Which- ,The apparatus shown generally comprises a work table Ill providedV at suitable longitudinal I intervals in its upper surface with feed rolls il, and in its longitudinal central portion with a conveyor belt I2, driven vby meansof a pair of 4suitable pulleys I3.' Idle rollers I4 cooperate with each ofthe feed rolls` II and it Willbe seen that these rollers together' with the conveyor belt I2 serve to provide means for longi tudinally feeding the trim panels along the work table at a substantially constant rate of speed. The' feed rollers II and conveyor belt I2 may all be driven by any suitable means, such, for example, as the electric motors |5 and I6. At the rear end of the table I0, substantially in the surface theerof, is a pair of feed rollers 210 which may, if desired, be driven by means of a suitable belt 2| from the conveyor rollers I3. Located above the table I0, at the rear portion thereof, is a fluid reservoir 22 adapted to contain a suitable supply of liquid adhesive, and has mounted for rotation therein a pickup roll 23 which may be driven by the belt 2| serving to drive the feed rolls 20. This pickup roll 23 serves to take up the liquid adhesive from the reservoir 22 and pass this adhesive to an adhesive applying roll 25 which is mounted for rotation directly above and between the'drive rollers 20. This adhesive applying roll 25 may be accurately adjusted with respect to the drive rollers in order that as a backing sheet 26 is inserted between these rolls, as shown, the sheet as a whole will be fed forwardly along the table and adhesive from the adhesive applying roll will be applied uni formly over'the surface thereof.

It will be seen that as these backing sheets 26 are fed forwardly alongthe table by means of the adhesive applying roll 25 and the feed rollers 20, they will be projected suiiiciently'far along the table to be carried forwardly by the conveyor belt I2.

Lcated direcuy above the centranportmn of able apparatus may be used for performing this operation, in the drawing is shown a jute macerating machine 30 into which may be feld brous material. is torn and shredded until thebers are all distributed at random and fed out-of the machine onto a conveyor belt 3| which may be supported ori a roller 32 mounted in suitable brackets above the conveyor I2. The brous material, as it comes from the jute shredding machine, will lie in a relatively thin matted layer on the surface of the belt 3|. The belt 3|, at its outer end, preferably passes over a roller 34 which is mounted in a pair of arms 35 pivoted in the bracket 33. Any suitable means, such, for example, as the motor and cam mechanism generally designated as 36, may serve to reciprocate the outer end of the belt in order that the matted mass of fibrous material carried by th belt 31| will be distributed uniformly over the vadhesive coated backing sheet 26 passing along the conveyor I2. This mechanism serves to provide means by which a loose matted layer of fibrous material will be placed on the adhesive coated sheets as they pass beneath this apparatus. For the purposes of the present invention, it is preferable that the rate of reciprocation of the belt 3| with respect to the rate of longitudinal movement of the conveyor belt I2 is such that approximately three layers of matted fibers will be placed on the surface of each of the sheets as they pass thereunder. The length of the reciprocatory movement of the belt 3| is sufficiently long so that the fibrous material will be distributed in an area slightly beyond the marginal lateral edges of the backing sheets in order that these sheets may be positively `uniformly covered throughout their body portion.

Fibrous material fed into this machine After leaving the conveyor belt I2, the sheets are picked up by the first of the three drive rollers and the matted bers are compressed between this drive roll I and its idle roller Ill, thus compacting these fibers and causing them to become strongly adhesively bonded to the backing sheets on which they have been distributed. i

The sheets are now fed over a pair of brushing rollers 4|) and 4| which are preferably driven to rotate in opposite directions and which serve to grip the fibrous material in the space between two adjacent sheets and serve to trim the excess brus material from these edges. The brushes and 4| preferably extend transversely across the work table and are of a length slightly wider than the backing sheets being prepared. In order to insure proper engagement of the brushes 4|! and 4| with the top and bottom edges of the sheets under treatment, rolls 40a and @la are mounted above the brushes 4|) and 4|. These rolls are preferably formed of soft resilient material such, for example, as sponge rubber, and are preferably driven in a direction to aid in feeding the backing sheets along the work table. It will be clear that as the backing sheets pass over the brushes 40 and 4|, these brushes will remove the excess fibrous material from the marginal edges -of the sheets, this excess material being resiliently forced into engagement with the brushes by means of the rolls 40a and 4 la. While any suitable means such as a mechanical conveyor may be used for returning the excess brous material, it has been found satisfactory to use pneumatic means. The brushes 40 and 4| are preferably mounted in a suitable housing 43 which has a duct 44 communicating therewith, which communicates with a blower 45. This blower is preferably run by a suitable electric motor 46 and may be operated during the operation of the machine. It will be appreciated that this blower provides means in addition to the rolls 40a. and 4|a described above for urging the fibrous material into engagement with the brushes. The blower is connected by means of a suitable duct 41 to the jute macerating chamber 30 in order that the fibers brushed from the edges of the sheets will be returned and subsequently used on other sheets. After the brushes 4| and 40 have served to brush the superfluous fibers from the top and bottom edges of the o tric motors 52 mounted on the frame work 5| and transmit drive to the brushes by means of belts 53. A conduit 55 serves to house each of the brushes 50 and this conduit preferably connects with the conduit 44 which, as has been explained above, constitutes the inlet for the blower 45. It will be appreciated that some suction pressure is applied to the fibrous material brushed from the side ymarginal edges of theI sheets by the brushes 50 and consequently all of the fibrous material brushed therefrom will be drawn down into the conduit and returned to the jute macerating machine. The drive rollers II' cooperating with their respective idlers I4 serve to additionally compact and consolidate the mass of fibers adhesively secured to the backing sheets during these trimming operations, and it will be appreciated that as the sheets leave the machine, a substantially uniform layer of soft, non-woven fibrous material will be adhesively secured to each of the backing sheets and that the marginal edges of these sheets will be neatly brushed in order that they will be ready for the mounting of the fabric inner trim material thereon.

It will be understood that the fibers in their loose, non-woven condition will be drawn into engagement with each of the trimming brushes by the suction set up in the conduits 44 and 55 and this suction will serve materially in aiding the removal of the excess fibrous material from the backing sheets. As has been brought out heretofore, it is highly desirable in the preparation of padded backing sheets of this type that` the marginalA edges of the sheets prepared will have a uniform structure.

It will likewise be appreciated that the suction pressure to which the edges of the sheets are subjected may be varied as may be desired by regulating the speed of the blower. In practice it has been found that if the fibrous material used is suflciently light, the rotary brushes may be dispensed with and the suction of the blower utilized as the sole means for trimming the marginal edges of the sheets.

From the foregoing it will be appreciated that the present invention provides a method which is very effective for rapidly and satisfactorily producing substantially uniform padded inner trim panels. l

The method described above is of course merely illustrative of the generic inventive concept presented herein and many modifications thereof falling within the scope of the subjoined claims will be apparent to those skilled in the art.

I claim:

l. The method of preparing inner trim panels which comprises coating a relatively stiff backing sheet with adhesive, distributing a layer of loose non-woven, fibrous material thereon, consolidating said fibrous material to eifect a strong adhesive bond with said backing sheet, passing said padded backing sheet between a pair of relatively movable brushes, resiliently urging said movable brushes into engagement with the lateral edges of said backing sheet as said backing sheet isI passed therebetween whereby said brushes will serve to trim the excess fibrous material from ,the marginal edges of said backing sheet.

2. The method of preparing padded inner trim panels which comprises coating a relatively stiff backing sheet with adhesive, distributing a layer of loose non-Woven, fibrous material thereon, consolidating said fibrous material to effect a strong adhesive bond with said backing sheet, passing said backing sheet over a pair of rotatable brushes with the padded side of said backing sheet disposed opposite to the side thereof which engages the brushes, rotating said brushes in opposite directions whereby to trim the excess fibrous material from the marginal edges of said backing sheet.

3. The method ofpreparing padded inner trim panels which comprises coating a relatively stiff backing sheet with adhesive, distributing a layer of loose non-woven, fibrous material thereon, consolidating said fibrous material to effect a strong adhesive bond with said backing sheet, $0

passing said backing sheet over a pair of rotatable brushes with the padded side of said backing sheet disposed opposite to the side thereof which engages the brushes, rotating said brushes in' CLARENCE W. AVERY. 

